Packaging incorporating serrated cutting edge and method of forming same

ABSTRACT

A package or carton is provided that incorporates a cutting edge without the need for a separate cutting element. The front panel of the package has an upper exposed end that is formed into a cutting edge by a plurality of complementary and opposing pair of cutting teeth. The package is especially adapted to hold material that is stored in a roll. A selected length of the material can be separated from the roll by pressing the material against the cutting edge and pulling the length of material thereby cutting the material in a linear fashion. The package of the present invention provides a more economical and environmentally friendly packaging solution with an integral cutting feature.

FIELD OF THE INVENTION

The present invention relates to cartons or packages, and more particularly, to a carton or package especially adapted for storing a roll of material such as aluminum foil or waxed paper, and that incorporates a cutting feature that does not require a material different than the packaging material used for the package.

BACKGROUND OF THE INVENTION

Packaging for aluminum foil, waxed paper, or other rolls of material is typically formed in a rectangular box or package, and the free end of the material is dispensed through an opening in the front or top of the packaging. The packaging may also include a cutting feature, referred to as a cutting bar or cutter bar made from a strip of metallic material that is adhered to a front dispensing edge of the package. The cutter bar typically has a serrated cutting edge that allows the product to be cut when a user places the product in contact with the cutter bar. The user can then detach a selected length of the product away from the roll.

Recent trends in packaging emphasize the use of less material in packaging not only to save costs, but also to be more environmentally friendly by consumption of fewer resources. As those skilled in the art can appreciate, the requirement to attach a metallic cutter bar to the packaging adds to the cost of the packaging and requires additional material. As compared to the packaging material, the cutter bar is an expensive component of the packaging.

Therefore, there is a continuing need to provide a more cost effective method of packaging rolls of material such as aluminum foil. However, there is also a continuing need to provide a means by which the material may be cut into selected lengths for easy dispensing by the user.

SUMMARY OF THE INVENTION

In accordance with the present invention, a package or carton is provided for storing a roll of material such as aluminum foil, and wherein a serrated cutting edge is provided on the packaging material without the requirement to use a separate cutting element such as a cutter bar.

In a preferred embodiment of the present invention, a cutting edge is formed at an upper front edge of the package. The cutting edge is formed by a zigzagged shaped perforation pattern. The perforation pattern is discontinuous, and segments of the perforation patter are interconnected by a plurality of fold segments. The fold segments longitudinally bisect the perforation pattern and the fold segments extend linearly.

When the package is folded along the fold segments, the perforation pattern creates a plurality of teeth like projections having an overlapping complementary pattern resembling a serrated edge. The teeth like projections or serrations form an effective cutting edge on the carton that eliminates the need to provide a separate cutter bar. Thus, the package/carton of the present invention can be formed of a single, continuous piece of material that saves on material costs, and provides a more environmentally friendly packaging solution.

An overhang that extends forward of the perforation pattern is secured against an interior surface of the front panel to maintain the cutting edge in its fully projecting configuration. The overhang can be secured to the front panel by an adhesive. An overage of adhesive may be applied, such that the adhesive extends along selected lengths of the cutting edge to provide additional stiffening to the teeth.

The packaging material may be a known paperboard or fiberboard material, or others. One side of the material may be laminated in order that printing may be applied to that side. The height, width, and pitch angle of the individual teeth may be modified to best separate the particular material that is packaged. For example, with respect to more resilient, flexible material such as waxed paper or parchment paper, it may be more advantageous to provide projections or teeth that are shorter, and that have a greater base size. For other material that may be difficult to cut without a sharp pitch to the teeth, such as aluminum foil, it may be advantageous to provide greater pitch angles, and greater heights of the cutting teeth.

Various other features and advantages of the present invention will become apparent from a review of the following detailed description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a blank of material used to form the carton of the present invention;

FIG. 2 is a greatly enlarged portion of FIG. 1 illustrating the arrangement of the fold segments and perforation pattern that forms the projections or teeth of the cutting edge of the present invention;

FIG. 3 is another plan view showing the blank folded along the fold segments that forms the cutting edge

FIG. 4 is a perspective view of the carton of the present invention in folded form, illustrating also a roll of product or material contained therein;

FIG. 5 is a greatly enlarged fragmentary perspective view of a portion of FIG. 4, illustrating the complementary and overlapping arrangement of the teeth or projections that form the cutting edge; and

FIG. 6 is a perspective view of a prior art carton that incorporates a traditional cutter bar made from a strip of metallic or plastic material secured to a front panel of the carton.

DETAILED DESCRIPTION

Referring first to FIG. 6, a prior art packaging carton 100 is illustrated. This carton is especially adapted for holding a roll of material, such as aluminum foil 101. The prior art carton includes a top panel 102, a front closing flap 104, an optional front closing flap extension 106, a rear panel 108, a bottom panel 112, and a front panel 118. The carton is made from a paperboard or fiberboard material. Fold lines are provided so that the carton may be folded into its final product shape. A plurality of flaps (not shown) extending from opposite side edges of the panels allow respective end panels 110 to be formed by folding the panels inward. A cutter bar 120 is attached to the upper edge of the front panel 118. The cutter bar includes an exposed edge having a plurality of continuous teeth/serrations 122. When the material 101 is extended over the cutter bar, a user may cut a selected length of material by pulling the material against the teeth 122. The prior art shown in FIG. 6 is exemplary of common packaging for not only aluminum foil, but other materials such as plastic, and waxed paper.

Referring to FIG. 1, a blank of material is shown in a cut pattern that is used to form the package/carton of the present invention. The blank shown in FIG. 1 includes a plurality of folded parts, referred to below as a collection of designated panels and flaps. A plurality of fold lines 11 delineate the locations where the panels are folded to form the folded package. More particularly, the present invention comprises the following components: a top panel 12, a front closing flap 14, an optional front closing flap extension 16, a rear panel 18, a pair of optional opposing rear panel closing flaps 20 formed on opposite lateral sides of the rear panel 18, a bottom panel 22, a pair of optional opposing bottom panel closing flaps 24 formed on opposite transverse edges of the bottom panel, a pair of optional bottom panel closing flap extensions 26, a front panel 28, and a pair of optional opposing front panel closing flaps 30 formed on opposite transverse edges of the front panel 28. The front panel 28 has a zigzagged patterned perforation line 32. The perforation 32 is discontinuous, and is separated and by a plurality of linear extending folded segments 34. Thus, the perforation line 32 is divided into sections that extend linearly or straight, and substantially parallel with the fold line 11 which separates the bottom panel 22 and the front panel 28. The perforation 32 and fold segments are illustrated in more detail in FIG. 2. As shown, the fold segments 34 bisect opposing pairs of teeth that extend laterally or transversely away from an axis defined by the fold segments 34. The teeth or extensions may be further defined as triangular-shaped extensions having respective apexes 44 and 46, as well as respective bases 42 and 48. As also shown in FIG. 2, each of the teeth/extensions have a height H that can be measured generally between the base and apex of the measured extension. Each of the teeth/extensions may also be defined as having a width W that is measured between lateral edges of the base. The teeth/extensions may have a particular pitch angle, which is preferably uniform. The pitch angle can be measured, for example, by angles A1 and A2 which in FIG. 2 are shown as arcs subtending the angles between either side of a perforation forming one side of a tooth/projection and the fold segment 34 or extension of the fold segment (shown in dotted line).

Referring to FIG. 3, the blank has been folded along fold segments 34 to create the cutting edge. The overhang 40 forward of the fold segments 34 is folded to the inside of the carton, and is secured by adhesive applied to the overhang and/or the interior surface of front panel 28.

Referring to FIG. 4, the carton of the present invention has been fully assembled in which the panels have been folded along their respective fold lines, and the flaps 20, 24, and 30 are folded inward to form opposite closed ends 36 of the package. The cutting edge extends along an upper edge of the front panel. A product P is placed in the package in the conventional manner for dispensing. If a length of material from the product P is to be dispensed, a desired length is cut by pulling the material against the cutting edge.

Referring to FIG. 5, when the package of the present invention is assembled, the teeth/extensions overlap as shown such that the lowest points or channels of one group of teeth vertically align with the opposing apexes of the other set of teeth. Thus as shown from the view of FIG. 5, the channels 48 vertically align with the apexes 44. Dotted lines 50 show the vertical alignments. Dotted lines 50 also extend perpendicular to the dotted line 52 that extends parallel to the long axis of the package. The complementary arrangement of the apexes 46 and 48 form an effective cutting edge for cutting the material.

In accordance with the method of the present invention, a carton blank is provided with the panels as shown in FIG. 1. The carton is folded along the designated fold lines 11 and fold segments 34. In order to provide additional structural rigidity to the teeth, just prior to folding along fold segments 34, adhesive may be applied along the perforation/cut line 32. Excess glue applied to the perforation/cut line 32 can be removed as by wiping. The dried adhesive remaining on the teeth. provides additional support to the teeth.

By the unique arrangement of teeth formed by the perforations 32, a linear extending and complementary group of cutting teeth are formed. The overlapping arrangement of the opposing sets of teeth provide structural rigidity, it being apparent that the back-to-back arrangement of the material in a double layer provides additional strength. Thus, the cutting feature of the present invention eliminates the need for a separate cutter bar and simplifies overall packaging assembly.

While the present invention has been disclosed with respect to a preferred embodiment, various changes may be made to the invention commensurate with the scope of the claims set forth herein. 

1. A package for holding a roll of material therein, said package comprising: a plurality of panels including opposing front and rear panels, opposing upper and lower panels, and opposing end panels formed by flaps extending from at least two of the panels, said plurality of panels when assembled along respective folded edges forming the package enclosing an interior open space therein; and said front panel having a plurality of perforations interconnected by a corresponding plurality of linear extending fold segments, said perforations having a zigzagged pattern forming a plurality of apexes and bases, said front panel being folded along said linear extending fold segments to form a cutting edge and wherein complementary groups of teeth are formed from said perforations.
 2. A package, as claimed in claim 1, wherein: said cutting edge comprises a first pair of teeth each having corresponding apexes, and a second pair of teeth each having corresponding apexes, and wherein said apexes of each pair are staggered from one another and substantially evenly spaced from one another along said cutting edge.
 3. A package, as claimed in claim 1, wherein: an overhang extends from said perforations, and said overhang is folded back against said front panel and adhered thereto.
 4. A package, as claimed in claim 1, wherein: said cutting teeth have pitch angles defined by angles A₁ or A₂, and which define an angle at which edges of the teeth extend from a line drawn parallel to a longitudinal axis of the package.
 5. A package, as claimed in claim 4, wherein: said angles A₁ and A₂ are substantially equal.
 6. A package, as claimed in claim 4, wherein: said angles A₁ and A₂ are different.
 7. A package, as claimed in claim 4, wherein: said teeth each have a height H substantially equal to one another.
 8. A package, as claimed in claim 4, wherein: each of said teeth have a width W that is substantially equal to one another.
 9. A package, as claimed in claim 1, wherein: an apex of each of said teeth and a channel between an opposing pair of teeth are vertically aligned.
 10. A method of forming a package for holding a product such as a roll of material to be dispensed from the package, said method comprising the steps of: providing a plurality of panels to enclose an interior open space in which a roll of material is stored; forming a discontinuous zigzagged perforation pattern on a front panel; and folding the front panel along fold segments disposed between perforations to expose a plurality of complementary extending teeth formed from the perforation pattern, and securing an overhang of said front panel against an interior surface of said front panel.
 11. A package for holding a roll of material therein, said package comprising: a plurality of panels forming the package enclosing an interior open space therein; said plurality of panels having a front panel and said front panel including a plurality of perforations interconnected by a corresponding plurality of linear extending fold segments, said perforations having a zigzagged pattern forming a plurality of apexes and bases, said front panel being folded along said linear extending fold segments to form a cutting edge and wherein complementary groups of teeth are formed from said perforations.
 12. A package for holding a roll of material therein, said package comprising: a plurality of panels forming the package enclosing an interior open space therein; said plurality of panels having a front panel and said front panel including means for forming a discontinuous zigzagged cut pattern interconnected by a corresponding plurality of linear extending fold segments, said front panel being folded along said linear extending fold segments to form a cutting edge by said means for forming that extend to create interlocking teeth. 